Electric riveting



July 1 s. H. PHELPS 3130mm alumina #1196 Feb. 25,

5 shuts-snag: "1 Y INVENTOR iaear fi/ezps TTORNEY July 2, 1940- G. H. PHELPS ELECTRIC RIVETING' Fi led Feb. 25. 1958 -s Sheets-Sheet 2 INVENTOR faeai/ifi/z s A ORNEY 5 Sheets-Sheet 3 G. H. PHELPS ELECTRIC RIVETING Filed Feb. 25, 1958 July 2, 1940.

I INVENTOR 662865 6/7/5425 TORNEY y 2, 1940- G. H. PHELPS 2,206,426

ELECTRIC RIVETING Filed Feb. 25, 1938 s Sheets-Sheet] A. C. Gnu/7467012 v I J 750 a/YIYJ /500///15 RNEY'-- Patented July 2, 1940 UNITED STATES 2,206,428 ELECTRIC arvlsme 'Gcorge'H. Phelpa Floral Park, N. Y., assignor to Metropolitan Device Corporation, a borporation of New York hppllcation February 25,1938, Serial No. 192,454

4 Claims. (01. 219-2) The invention herein disclosed relates to heading rivets and includes a machine for this purpose which, while not limited thereto, is par ticularly suitable for riveting parts to a frangible base.

Commonly, solid rivets have heretofore been headed by striking the end of the heated rivet. The blows on the end of the rivet upset the metal and form a head on the rivet. This formed head together with the preformed head on the opposite end of the rivet secures together the parts through which the rivets pass.

The heading of rivets in this manner is not particularly suitable where the rivet is used to is secure parts to a-frangible base, as, for example, in assembling switches, fuse blocks and other electrical accessories in which the parts are secured to bases of insulating material such as porcelain. In such cases, even slight blows so may fracture or break the base to which the parts are secured and it is an object of this invention to provide a way in which parts may be riveted to a frangible base without danger of breaking or fracturing the base and also a machine for performing such work.

In accordance with the invention rivets are headed by pressure. A'rivet is placed through openings in the parts to be secured thereby and subjected to pressure. When the pressure on the ends of the rivets reaches a predetermined value, the rivet is subjected to heat and its temperature raised to the point where its compressive strength will no longer support the load. At this point upsetting of the rivet begins and continues until the heating is interrupted which takes place when the end of the rivet is headed and the rivet clamps the parts together. Heading of rivets in this manner is accomplished by the machine of this invention which includes means for exerting pressure on the ends of the rivet and means for heating the rivet for a predetermined time interval determined by the nature of the metal of the rivet.

Such a machine constructed in accordance with this invention is illustrated in the accompanying drawings in which:

Figs. 1 to 3 illustrate the assembled machine, Fig. 1 being a front elevation, partly in section, Fig. 2 being a transverse section taken on line 2-'! of Fig. l, and Fig. 3 being a plan with parts broken away to show parts lower in the machine;

Figs. 4 to 6 illustrate several positions of the mechanical parts that engage the ends of a rivet; Fig. 4 is a fragmentary, sectional elevation illusafter the upsetting of the rivet.

. Figs. 7 to 1 0 illustrate certain parts of the machine, Fig. 7 being a longitudinal section of the pressure operated mechanism of a pressure actuated switch, and Figs. 8, 9 and 10 being respectively a side elevation, an end elevation 10 (both partly in section) and a transverse section (taken on the line lll--l0 of Fig. 8) of a relay mechanism;

Fig. 11 is a wiring diagram illustrating the electrical circuits and equipment forming a part 15 of the machine; I

Figs. 12 and 13 illustrate the manner in which some devices are mounted on the machine for having parts thereof riveted together, Fig. 12 being a fragmentary plan of the plate of the 20 machine, and Fig.- 13 being a. fragmentary section illustrating a connector block with rivets therethrough on the machine;

Figs. 14 and 15 illustrate, by way of example,

some work that may be-done on the machine; 25

Fig. 14 is a bottom plan of an electrical connector block, and Fig. 15 is an isometric of the same. a

The machine together with the associated mechanism, with the exception of a foot con- 30 trol, is mounted upon a table frame I. For the purpose of exerting pressure onthe ends of a rivet, there are provided two opposed and aligned rods 2 and 3, the ends of which engage the ends of a rivet to be headed. The lower rod 3 is sta- 35 tionary, being mounted upon the table frame I, and the upper rod 2 is movable. This latter rod is moved into contact witha rivet between the two rods, and thereafter, while further movement is resisted by the rod 3, a compressive force 0 is exerted on the rivet through the medium of the rod 2. This movement and the application of a compressive force to the rivet is effected through a fluid operated mechanism.

One end of the rod 3, which extends vertically, 45 is threaded into the end of a hollow boss 4 that extends vertically from a block 5. The block 5 is mounted on the table frame I and has a vertical recess 5a therein in which the end of the from a conduit 1 that passes through the'bloclr and into the recess 5a.. The external diameter 55 of the jet is less than the internal diameter of the recess 5a and an annular passage is thus formed for the cooling water that enters through the conduit 1 and that is ejected against the end of the rod 3 within the boss 4. This annular passage is connected to a conduit 8 throush which the water is carried to waste.

The rod 2 is mounted on a cross-head 9 that extends between and is secured two vertical rods l0 and II. This rod 2 is lik wise threaded into the hollow end of a boss l2 that is received and secured in a recess in the cross-head. The rods l0 and H are electrically insulated from the cross-head 9 by flanged bushings i3 and M in the openings in the cross-head through which the ends of the rods extend. These rods extend through and are slidably mounted in the table frame I and a guide plate ii-"below and spaced from the table frame I. A cross-head l6 extends between and is secured to the lower ends of the rods I0 and I I. It is through this cross-head that the rods are moved to bring the rod 2 into contact with the end of a rivet.

The fluid operated'mechanism for moving the rod 2 and applying a compressive force on a rivet is mounted beneath the table frame i. It consists of a cylinder l'l mounted between plates I8 and I9 constituting cylinder heads. The plate I8 is backed against the lower surface of the table frame I and has an annular groove in which the upper edge of the cylinder IT is received; The

' plate I9 is against the guide plate l5 and it has an annular groove in which the lower end of the cylinder is received. The whole is secured together and the. guide plate secured in place by bolts 20 extending through the guide plate and threaded into the table frame I, and tightly securing the several parts together as well as supporting the guide plate and the cylinder. Within the cylinder there is a piston 2| from which a piston rod 22 extends. The piston rod 22 extends through the cylihder head l9 and the guide plate I5 and by means of a connecting rod 23, it is connected to the cross-head "5. Ports, for the. admission and exhaust of air under pressure, are

provided in the cylinder heads l8 and l3. 7

The admission of air under pressure'to and the exhaust of air from the cylinder I1 is controlled by a valve 24 mounted on the floor. This valve. the details of which are shown diagrammatically in Figure 11, consists of a case 25 having ports 26a and 26b therethrough. A rotary valve 21 within the case controls communication between the air under pressure, represented by a flexible conduit 29 (see Figure 1), and the ports in the cylinder heads' and communication between these latter ports and the atmosphere through a vent 3B. The rotary valve is movable in one direction by a foot pedal 3| and in the other direction by a spring '(not shown). The valve has an axial passage 32 that is connected through flexible conduit 33 (see Figure. 1) to the air supply. With this passage two radial passages and 35, angu larly displaced, communicate. A passage 36 in the periphery of the valve communicates with the atmosphere through the vent 30. The ports 26a and 26b are respectively connected, through flexible conduits 26c and 26d respectively, to the ports in the cylinder heads l9 and I8. Thus, when the pedal 3| is raised, the passage 34 in the valve communicates with the port 26a and air under pressure is delivered to the lower end of the cylinder I'I.

In this same position, the port 2627' phere. The piston is thus raised in the cylinder and the rods 2 and 3 are in the position shown in Figures 1 and 4. When the pedal 3| is pressed, the valve 21 is rotated so that the passage. registers with the port 26b and the passage 36 registers with the port 26a. In this position of the valve, air under pressure is delivered to the upper end of the cylinder and the lower end of the cylinder is connected to the atmosphere.

Intermediate the cross-head 9 and the table frame I, there is a work-support plate 31 on which the parts to be riveted together are placed. This plate is mounted on heavy springs 38 that rest on the table frame I and it is positioned such that-the rod 3 normally extends through an opening 31a through the plate, particularly when the machine is used for the type of work hereinafter described. Within each spring 38, there is a cupshaped element 39 that is,secured in an opening heads of the bolts 40 and the bottom of the cupshaped elements 39 serves to limit the upward movement of the plate 31 under the action of the springs 38.

In use, the parts to be riveted together (see Figures 4 to 6) are placed on the plate 31, the parts being positioned with respect to each other and a rivet inserted in the aligned openings. As shown in Figure 4, a contactor block 41 is positioned on the plate 31'. A contact strip 42 is to be riveted to the block and the rivet "extends through aligned openings in the strip and block. When the block is positioned with the rivet 43 aligned with the rods 2 and 3 the operator presses the foot pedal 3|. This, as heretofore explained, causes the piston 2| to move downwardly in the cylinder and through the rods I0 and H and the cross-head 9 carries the rod 2 towards the rod 3. When the rod 2 engages the formed head on the rivet 43, it continues to move downwardly compressing the springs 38 until the unheaded end of the rivet engages the rod 3. The pressure of the springs 38 serves to clamp the strip 42 in contact with the block 4| while the heading of the rivet takes place.

When the rivet 43 engages the rod 3, as shown in Figure 4, further movement of the rod 2 is resisted and pressure is built up in the cylinder ill behind the piston. This pressure is translated into a compressive force on the rivet and when this force attains a predetermined value, the rivet is heated for a definite predetermined time period. The extent to which the rivet is heated is such that it is upset under the compressive force on the rivet, and a head 43a is formed thereon as shown in Figure 6.

This heating of the rivet is effected by passing an electric current through the rivet. For this purpose there is provided a transformer 44 hav-' ing a tapped primary 44a and a single turn secondary b. In a machine for riveting the parts of a fuse block, connector block and the like to porcelain bases, this transformer, which may be supplied from a 220 volt A. C. supply represented by line wires 45 and 46, is preferably one having eighty turns on the. primary tapped at intervals of five turns, the last tap being at forty turns.

In such case, the secondary has a single turn of 7 one-quarter inch by four inch bus bar. In the arrangement shown diagrammatically in Figure 11, one of the supply wires 46 is connected to one side of the primary a. The other supply wire is connected to the armature 41a of a normally open, single-pole, single-throw, electromagnetically operated switch 41. The arinature 41a cooperates with a contact 41b. which is connected by a wire 48 to the movable arm 49 that engages the several contacts of the transformer primary. A spring 50 normally'maintains the armature 41a away from the contact 41b. The force of the spring is overcome and the ficuit to the primary or the transformer closed upon energization of the coil 410 of the switch 41. I

The secondary of the transformer extends to the rods 2 and 3, one side of the secondary being connected to the rod 2 by a heavy flexible lead 5! and the other side being connected to the rod 3 by a bus 52 that passes through a magnetic selector 54 hereinafter more particularly described.

Thus, when the rods 2 and 3 engage the ends of a rivet the secondary circuit of the transformer is closed and the rivet forms a part of'that circuit. Upon the subsequent closing of. the primary circuit current flows through the rivet and effects the heating of the rivet.

Energization of the coil 41c of the electromagnetic switch 41, and therefore energization of the transformer primary, is determined by the pressure in the cylinder l1 above the piston 2 I. When this pressure reaches a predetermined value, and in consequence when a predetermined compressive force is applied to the rivet, a circuit to the 'coil 41c is closed by a pressure actuated switch 55. The switch may be of any well known type and it is represented diagrammatically in Figure 11 as a pivotally mounted arm 55a operating between two contacts 55b and 550. Normally, that is, when there is no pressure in the upper partof the cylinder l1, or when the pressure is insufficient to actuate the switch, the switch arm 55a makes contact with the contact 55c. The switchis operated to move the arm into contact with the contact 55b by a pressure diaphragm device in detail in Fig. 7.

This device consists of a circular case 51 having a cover 58 that abuts against a shoulder formed on the case. Between the shoulder and the cover. a flexible diaphragm 59 is clamped between circular gaskets 88, one on each side of the diaphragm at the edge thereof, the gaskets and the edge of the diaphragm being clamped between the shoulder on the case and the cover by bolts ii. there is formed an outwardly extending lateral boss 58a into threaded. 0n the other end of the tube there is threaded a T-fltting 83, the side opening 69a of which is connected by a conduit 84 to a port in the cylinder head I8. In the opening-63b of the fitting 88, opposite to that into which the 58, illustrated diagrammatically in Fig. 11 and tube 82 is threaded, there is threaded a plug 85' bored to receive a rod 88 and recessed and threaded to receive a packing gland 81, the bushing 58 of which is likewise bored to receive the rod 88..

The end of the rod 88 passing through the plug 85 is. threaded and a nut 89 threaded thereon abuts against the end of the bushing 88. Inside the tube 82 the rod 88 is connected to one end of a spring 18, the other end of which spring is secured to one end of a rod 1| that passes through the diaphragm 59 and an opening in the wall of the case 51. The rod 1| is positioned with respectto the diaphragm bycollars 12 .secured on the rod, one on each side of the diaphragm. It will thus be seen that fluid under pressure entering through the conduit 64 from the cyl On the cover, centrally thereof,

which one end of a tube 82 is inder I1 acts on the diaphragm 59 in opposition to the tension-of the spring 18. When the pressure exceeds the tension of the spring, the diaphragm will flex, raise the rod 1| and so actuate the switch 55. The tension of ,the spring 10 may, of course, be adjusted through the nut 89.

The circuit closed (see Fig. 11) by actuation of the switch 55 through the pressure devices includes a source of direct current represented by the positive line wire 18 and the negative line wire 14. The positive-line wire is connected directly to the contact 55b. The arm orblade 55a of the switch 55 is connected by a wire 15 to the arm or blade 18a of a double-throw, single-pole, electromagnetic switch 18. The arm 18a of the switch 16 is normally held in engagement with a contact 16b which is connected by a wire 11 to one side of the coil 410 of the electromagnetic switch 41, a fixed resistance 18 being interposed in series with the coil. The other side of the coil 41c is connected directly to the negative line wire 14.. i

This circuit to the coil 41c of the switch 41 is openedafter the lapse of a predetermined time interval by energization of the coil 160 of the electromagnetic switch 16, which when energized moves the arm 18a away from the contact 18b and into engagement with a contact 18d. Energization oi the coil 16c is effected through the discharge of a condenser 19 through a pair of neon tubes 88 and 8|. Upon closing the-circuit to the coil 410 of the switch 41,-the condenser 19 begins to charge at a rate determined by theresistance of the charging circuit and when it has reached a potential of sumcient magnitude it discharges through the neon tubes to energize the coil 160 of the switch 18.

In the embodiment of the invention illustrated, there are two charging circuits for the condenser as this particular machine is designed for operating alternatively upon steel or brass rivets, both being used in securing parts of an electrical connector block, for example, to the porcelain base or together. Which circuit will be effective, and in consequence the time of heating of a'rivet, is determined by the magnetic selector 52. This device is essentially an electromagnetic switch or relay of the single-pole, double-throw type. The particular magnetic selector illustrated (see Figs. 8, 9 and 10) consists of a metal'yoke'82, one leg 82a of which has a lateral flange 82b. Through the channel.

formed by the web of the yoke, the leg 82a and the flange 82b, ,the bus 52 passes. It is secured to the leg82a by bolts 83, being electrically insulated therefrom by insulating material 84 and receivedin a liner 84a for the channel. The

end of the other leg 820 of the yoke isbifurcated and the edge 82d between the arms of the bifurcated end is brought to a knife edge. This edge forms a fulcrum for a lever 85 that is urged, against an adjustable stop 86 mounted in a plate 81 of electrical insulating material secured to the yoke. The stop 86 is a screw having a knurled end 88a and threaded through a block 88 mounted on the plate 81. The end of the lever 85 is bifurcated and straddles the plate 81. Opposed contacts 89 and 98 slidably mounted in the arms of the bifurcated end-of the lever and spring pressed by leaf springs 9| and 92 cooper ate with contacts 93 and 94', embedded in the plate 81. The lever 85 is held against the stop and the contacts 89 and 98 in engagement with the contact 93 by a spring 95 that is secured atone end to a rod 96 extending through and positioned by a nut 91 with respect to a bracket 98 mounted on the leg 92c of the yoke. The

other end of the spring is attached to a headedrod 99 extending through an opening in the upper end of the lever.

When a current of one intensity passes through the secondary circuit of the transformer, as, for example, when a steel rivet constitutes a part of the circuit, the magnetic force of the magnetic selector is insuflicient to move the lever 85 against the force of the spring 95 and contact 90 remains in engagement with contact 93. When, however, a rivet of a different metalwith lower electrical resistance, as for example, brass, constitutes a part of the secondary circuit, a greater current flows through the bus 52 and the lever 85 is moved "against the action of the spring 95 and contact 90 is-brought into engagement with contact 94. This changes the time interval during which current passes through the rivet by changing the resistance of the circuit through which the condenser 19 is charged.

Referring to Figure 11, it will be seen that upon the closing of the circuit to the coil 410 of the switch 41, there is established a circuit to the condenser 19. This circuit includes the wire 15, a wire I connected to wire 15 and one side of the condenser 19., A wire IOI is connected to the other side of the condenser and to one side of a fixed resistance I02. This resistance is connected by a wire I03 to the contact 93 of the magnetic selector 54. The circuit continues through the contact 90 of the magnetic selector and a wire I04 connectingthecontact 90 to one end of a variable resistance ,I0 5. The movableaarm of the variable resistance I05 is connected by a wire I06 to the negative line wire Thus, this charging circuit includes the variable or adjustable resistance I05 which may be set to determine the charging time .of' this circuit. When the arm 05 of the magnetic selector 54 is attracted and contact 90 engages contact 94, another charging circuit for the condenser including another variable resistance I01 is utilized for charging the condenser 19. This resistance is connected by a wire I08 to the wire I03 and the movable arm I09 thereof is connected to the wire I04. Under thiscondition the previously described charging circuit is broken at the contact 93 and contact 90 is directly connected to the wire I06 through the contact 94 which is, as shown, connected to wire I06. The charging circuit for the condenser 19 now in-'-' cludes wires 15, I00, condenser 19,'wire, IIII, resistance I02, wire I09, variable resistance I01, arm I09, wire I04, contact 90, contact 94 and wire I06 to negative line wire 14. This charging circuit thus includes the variable resistance I01 which may be set to determine the rate of charging of the condenser 19.

Whichever of the two charging circuits is effective, the condenser iseharged'to a point where it breaks down the resistance of the neon tubes and the discharge passes through the coil 16c of the switch 16. The circuit through which this takes place includes a wire 0 connected to the wire I00 and one side of the two neon tubes 60 and 6| which are connected in series. The other side of the neon tubes is connected by a wire III to one side of the coil "(2 and the other side of the coil 160 is connected by a wire H2 t'o'the wire IOI.

When the coil 160 is thus energized, it attracts the arm 16a which breaks the circuit to the coil 410 at the contact 1612 and engages the contact 16d thereby closing a holding circuit for the coil 160. This holding circuit includes wire 15, arm 16a, contact 16d, a wire H3 connected be tween contact 1612 and wire III, coil 16c, wire II2, wire IOI, resistance I02 and one or the other of the circuits above described through resistances I05 or I01 back to the negative line wire 14 depending upon which contact is engaged by contact 90 of magnetic selector 54.

Upon the release of the pressure in the cylinder I1, switch arm 55a separates from contact 55b and the holding circuit to coil 160 is broken at this point as well as the circuit to coil 41c of.

A to the condenser are thus shunted.

The timing circuits including the electromagnetic switch 16, the neon tubes 80 and 8|, the condenser 19, resistance I02, variable resistances I05 and I01 and a condenser 5 connected across the wires 11 and I06 are mounted in a box II6 that is secured to the table frame I. Shafts for rotating the movable arms of the variable resistances I05 and I01 extend through the box and have knurled knobs H1 and H9 thereon. The box is illustrated attached to the table frame in-Figures 1 and 3 and diagrammatically by the dotted line rectangle in Figure 11. The wires from the box II6 are connected to the circuit through a plug connector II9. This facilitates the removal and replacement of the timer.

In Figures 14 and 15 there is illustrated a connector block that includes a molded porcelain -base I having two longitudinal shoulders 120a and I20!) and a longitudinal projection I200 between and separating the shoulders. 0n the shoulder I20a there are two aligned electrical conductor strips HI and I22, the opposed ends of which are separated and have a substantially concaved semicircular configuration. Between the separated ends of these strips is a circular boss I20d formed on the base slightly less in height than the thickness of the strips. A brass rod I23 having one portion I23a threaded and a portion I23b of lesser diameter unthreaded extends through an opening in the base through posite recesses I20e into which part of the metal of the rod, in the upsetting operation described below, flows to form radial fins that prevent the rod from rotating. The strip I2I is secured to the base by a steel rivet I25 and the strip I22 is held to the base by a steel rivet I26. The assembly on the shoulder I20b, of the base in, all material respects, identical with that described on the shoulder I200.

In assembling the connector block described above thestrips are placed on the shoulder, the

rivet. I25 is inserted through the strip I2I and a hole in the base provided therefor. The strip I22 is likewise placed on the shoulder and the rivet I26 inserted through it and the base, and the rod I23 is inserted in the opening provided therefor. The parts on the shoulder I201; are

likewise assembled and the block is then placed on the riveting machine. With this block a plate I25 is placed upon the plate 31 to cover the larger opening 31a through the plate 31. The plate 8 I25 has an opening l25'a through which the rod 3 extends. The operator brings the rivet I28 into alignment with the rods 2 and 3 and presses the foot pedal 3|. In the manner heretofore explained the rivet is headed. The pedal M is re- 10 leased, the rods 2 and 3 separate and thebrass rod I23 is brought into alignment with the rods 2 and 3 when the pedal is again pressed. Upon the pressure switch 55 being closed the magnetic selector 54 operates as previously described to change the heating time to correspond with the electrical resistivity of the brass used. When this rod has been headed, the pedal 2| is again released and the rivet I25 is brought into alignment with the rods 2 and 3. Upon the opening of the primary circuit of the transformer 44 after the heading of the brass rod, the lever 85 of the magnetic selector is released and the timing circuit for a steel rivet is connected in circuit Upon again pressing the pedal 3|, the steel rivet I is headed, the magnetic selector not functioning. In the same manner, the parts assembled on the shoulder mm are secured to the base.

From the foregoing description of the embodiment of the invention illustrated in the drawings, it will be seen that there is provided a way in which and a machine by which parts may be riveted to a frangible base without danger of breaking or fracturing the base, and by means of which an assembly requiring several different kinds of rivets may be completed without readjusting the machine.

It is important to note that while the machine described has been described as a machine for a heading rivets, it includes all the essentials of a spot'or resistance welding machine. In fact machines such as that disclosed have been used for spot welding.

It will be obvious that various changes may I be made by those skilled in the art in the details of the invention as disclosed within the principle and scope of the invention as expressed inthe appended claims.

5 I claim:

9 1. 'In a riveting machine of the type described the combination comprising means for exerting pressure on the ends of a rivet, means for pallinganelectriccurrentthroughtherivottoheat the rivet, and control means therefor operative to cut on the current including a pair of control circuits, each circuit including means for cutting oifthe current after a predetermined interval, means for varying the time interval of 5 each circuit, and means for selectively rendering said circuits efiective in accordance with the current passing through the rivet.

2. In a riveting machine of the type described the combination comprising means for exerting l0 pressure on the ends of a rivet, means for passing an electric current through the rivet to heat the rivet, and control means therefor-operative to cut off the current including a pair of control circuits, each circuit including a condenser con- 15 nected in circuit to be charged, a variable remeans for varying the quantity of current passed through a rivet including a plurality of means each independently settable and operative to cut off the current of said electrical heating means after a predetermined time interval, and means operative in accordance with the current in the rivet circuit for selectively rendering said current cut 01! means effective.

4. In a riveting machine of the type described. the. combination comprising means for exerting pressure on the ends of a rivet, electrical heating means for passing an electric current through 40 the rivet to heat the same, and control means therefor independent of said electrical heating means for varying the quantity of current passed through a rivet including a plurality of control circuits each independently settable and operative' to cut off the current of said electrical heating means after a predetermined time interval, and a relay in the rivet circuit for selectively rendering said current cut 011. means effective.

onoaon a. PHELPS; 

